Yanmar 3TNV88C - Service Manual

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3TNV88C

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INDUSTRIAL ENGINES

SERVICE MANUAL

INDUSTRIAL ENGINES TNV Series

SERVICE MANUAL

0BTN4-G00201

PRINTED IN JAPAN

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Table of Contents7
Yanmar Warranties8
YANMAR Limited Warranty9
What Is Covered by this Warranty9
How Long Is the Warranty Period9
What the Engine Owner Must Do9
To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor10
What YANMAR will Do10
What Is Not Covered by this Warranty10
Warranty Limitations11
Warranty Modifications11
Questions11
Emission System Warranty12
YANMAR Co., Ltd. Limited Emission Control System Warranty - USA Only12
Your Warranty Rights and Obligations12
Manufacturer's Warranty Period12
Warranty Coverage13
Warranted Parts13
Exclusions14
Owner's Warranty Responsibilities14
Safety Statements17
Safety Precautions18
During Operation and Maintenance18
Component Identification33
General Service Information33
Location of Labels35
Engine Nameplate (Typical)36
Emission Control Regulations36
EPA/ARB Regulations - USA Only36
Emission Control Labels36
EPA/CARB Labels (Typical)36
The 97/68/EC Directive Certified Engines37
Engine Family37
Function of Major Engine Components38
Function of Cooling System Components39
Main Electronic Control Components and Features40
Installation Position of Sensors42
Crank Rotation Sensor43
Cam Speed Sensor43
New Air Temperature Sensor44
EGR Temperature Sensor44
Intake Temperature Sensor44
Fuel Temperature Sensor (Equipped on Supply Pump)45
Cooling Water Temperature Sensor45
Diesel Particulate Filter (DPF) Inside/Inlet, Exhaust Temperature Sensor46
Rail Pressure Sensor46
EGR Pressure Sensor47
Diesel Particulate Filter (DPF) Differential Pressure Sensor48
EGR Valve49
Intake Air Throttles50
Acceleration Sensor (YANMAR Standard)51
Diesel Fuel52
Diesel Fuel Specifications52
Filling the Fuel Tank53
Priming the Fuel System54
Engine Oil55
Engine Oil Specifications55
Engine Oil Viscosity55
Checking Engine Oil56
Adding Engine Oil56
Engine Oil Capacity (Typical)56
Engine Coolant57
Engine Coolant Specifications58
Filling Radiator with Engine Coolant58
Daily Check of the Cooling System59
Engine Coolant Capacity (Typical)59
Specifications60
Description of Model Number60
Engine General Specifications60
Principal Engine Specifications61
3Tnv88C61
3Tnv86Ct62
4Tnv88C63
4Tnv86Ct64
4Tnv98C65
4Tnv98Ct66
Set Output Listed by Rotation67
Engine Service Standards68
Tightening Torques for Standard Bolts and Nuts69
Abbreviations and Symbols70
Unit Conversions71
Periodic Maintenance74
Before You Begin Servicing75
Introduction76
The Importance of Periodic Maintenance76
Performing Periodic Maintenance76
YANMAR Replacement Parts76
Ask Your Authorized YANMAR Industrial Engine Dealer or Distributor for Help76
Required EPA/ARB Maintenance USA Only76
EPA/ARB Installation Requirements USA Only76
Periodic Maintenance Schedule77
Periodic Maintenance Procedures79
After Initial 50 Hours of Operation79
Check and Adjust Cooling Fan V-Belt81
Every 50 Hours of Operation82
Every 250 Hours of Operation85
Every 500 Hours of Operation88
Replace Fuel Filter89
Every 1000 Hours of Operation91
Change Coolant92
Adjust Intake/Exhaust Valve Clearance92
Every 1500 Hours of Operation93
Every 2000 Hours of Operation94
Every 3000 Hours of Operation95
Before You Begin Servicing99
Introduction100
Cylinder Head Specifications100
Adjustment Specifications100
Cylinder Head100
Intake/Exhaust Valve and Guide101
Push Rod102
Rocker Arm and Shaft102
Valve Spring102
Camshaft and Timing Gear Train Specifications103
Camshaft103
Idler Gear Shaft and Bushing104
Timing Gear Backlash104
Crankshaft and Piston Specifications105
Crankshaft105
Thrust Bearing106
Piston106
Piston Ring107
Connecting Rod110
Tappet110
Cylinder Block Specifications111
Cylinder Block111
Special Torque Chart112
Torque for Bolts and Nuts112
Special Service Tools115
Measuring Instruments119
Cylinder Head121
Cylinder Head Components121
Components of a Cylinder Head122
Disassembly of Cylinder Head123
Removing the Glow Plugs124
Removal of Valve Cover124
Removal of Rocker Arm Assembly125
Removal of Cylinder Head125
Disassembly of Rocker Arm Assembly125
Removal of Intake/Exhaust Valves126
Cleaning of Cylinder Head Components127
Inspection of Cylinder Head Components127
Inspection of Rocker Arm Assembly128
Inspection of Cylinder Head129
Reassembly of Cylinder Head132
Reassembly of Rocker Arm Reassembly134
Reassembly of the Valve Cover135
Measuring and Adjusting Valve Clearance136
Crankshaft and Camshaft Components138
Disassembly of Engine139
Disassembly of Camshaft and Timing Components140
Removal of Timing Gear Case Cover140
Checking Timing Gear Backlash140
Removal of Timing Gears141
Removal of Camshaft142
Disassembly of Crankshaft and Piston Components144
Removal of Crankshaft146
Inspection of Crankshaft and Camshaft Components147
Replacement of Crankshaft Oil Seals148
Measure Crankshaft Bearing Oil Clearance148
Inspection of Cylinder Block148
Inspection of Connecting Rod150
Inspection of Tappets151
Inspection of Crankshaft151
Inspection of Camshaft152
Inspection of Idler Gear and Shaft153
Honing and Boring153
Reassembly of Crankshaft and Piston Components154
Installation of Crankshaft157
Reassembly of Camshaft and Timing Components160
Installation of Gear Case160
Installation of Camshaft160
Installation of Timing Gears161
Installation of Gear Case Cover161
Installation of Oil Pan162
Final Reassembly of Engine163
EGR System164
EGR System (Typical Model)164
Typical Model for Turbocharger Model165
Disassembly of Supply Pump166
Cleaning the EGR Valves169
Lead Valves170
Precautions for Installation170
EGR Cooler170
EGR Pipe and Other Connecting Elbows171
Installing EGR Related Components/Parts171
Intake Throttle172
Precautions for Handling the Intake Throttle172
Fuel System173
Before You Begin Servicing175
System Structure176
Fuel System Specifications178
Torque Chart for Major Bolts and Nuts178
Fuel System Diagram179
Fuel System Components180
Removal of Common Rail181
Reassembly of Common Rail182
Removal of Injector183
Reassembly of Injector184
Removal of Supply Pump185
Reassembly of Supply Pump186
Cooling System189
Before You Begin Servicing191
Introduction192
Cooling System Diagram192
Engine Coolant Pump Components193
Engine Coolant System Check194
Engine Coolant Pump194
Removal of Engine Coolant Pump194
Disassembly of Engine Coolant Pump195
Cleaning and Inspection196
Temperature Switch196
Water Temperature Sensor196
Radiator Cap197
Reassembly of Engine Coolant Pump197
Installation of Engine Coolant Pump198
Lubrication System199
Before You Begin Servicing201
Introduction201
Oil Pump Service Information202
Lubrication System Diagram204
Checking Engine Oil Pressure205
Oil Pump Components205
3Tnv88C, 3Tnv86Ct, 4Tnv88C, 4Tnv86Ct205
Disassembly of Oil Pump205
Cleaning and Inspection206
Check Outer Rotor Outside Clearance206
Outer Rotor to Inner Rotor Tip Clearance206
Check Outer Rotor Side Clearance207
Reassembly of Oil Pump207
4TNV98C, 4TNV98CT (Trochoid Oil Pump)208
Disassembly of Oil Pump208
Cleaning and Inspection209
Check Rotor Shaft Clearance210
Reassembly of Oil Pump210
Before You Begin Servicing213
Introduction214
Specifications214
Turbocharger Service Information214
Troubleshooting215
Turbocharger Components217
Turbocharger Component Functions218
Theory of Operation219
Compressor Side Sealing Mechanism219
Waste Gate Modulation219
Washing Procedure220
Periodic Inspection221
Visual Inspection221
Inspection of Rotor Rotation221
Inspection of Rotor Play221
Removal of Turbocharger221
Checking Rotor Play222
To Check Rotor Run-Out222
Waste Gate Valve Test223
Waste Gate Actuator Leak Test223
Installation of Turbocharger223
Starter Motor226
Before You Begin Servicing227
Introduction228
Starter Motor Information228
3TNV88C to 4TNV86CT - Standard and Optional228
4TNV98C and 4TNV98CT - Standard and Optional228
Starter Motor Specifications229
Starter Motor Troubleshooting230
Starter Motor Components231
Starter Motor232
Removal of Starter Motor232
Disassembly of Starter Motor232
Cleaning and Inspection234
Reassembly of Starter Motor238
Check Pinion Projection Length239
No-Load Test240
Installation of Starter Motor241
Before You Begin Servicing245
Introduction246
Dynamo and Alternator Information246
3TNV88C to 4TNV98CT - Standard and Optional Dynamos246
3TNV88C to 4TNV98CT - Standard and Optional Alternators246
Alternator Specifications247
Dynamo Specifications247
Alternator Troubleshooting248
Alternator Components249
Alternator Wiring Diagram250
Alternator Standard Output251
Alternator252
Removal of Alternator252
Disassembly of Alternator252
Reassembly of Alternator254
Installation of Alternator256
Dynamo Component Location257
Dynamo Wiring Diagram258
Operation of Dynamo258
Dynamo Standard Output259
Testing of Dynamo260
Testing Stator Coil Continuity260
Testing Stator Coil Short-To-Ground260
Testing Dynamo Regulated Output260
Dynamo260
Removal of Dynamo260
Disassembly of Dynamo261
Reassembly of Dynamo261
Installation of Dynamo262
Electronic Control System263
Before You Begin Servicing265
System Structure266
Electronic Engine Speed Control267
Diesel Particulate Filter (DPF)269
Troubleshooting of Electronic Control System273
Fault Detection Capability273
Smartassist Direct (Sa-D)275
Replacement of Components276
Electronic Control Harness Connections280
Electronic Control Harness Connections285
Electric Wiring287
Electric Wiring Precautions289
Electrical Wire Resistance290
Battery Cable Resistance291
Electrical Wire Sizes - Voltage Drop292
Conversion of AWG to European Standards293
Failure Diagnosis295
Special Service Tools297
Tier 4 (BOSCH) Compression Inspection Procedures298
Measured Value and Troubleshooting300
Quick Reference Table for Troubleshooting300

Yanmar 3TNV88C - Service Manual

Table of Contents

Yanmar 3TNV88C Specifications

Related product manuals

Brand	Yanmar
Model	3TNV88C
Category	Engine
Language	English